I need some help with Predictive Maintenance. In our last TS audit we were sited for not having a predictive maintenance program. The auditor told us what were doing was tool changing.
We are a automotive wiring harness provider. We have Komax cutting machines, compressors, presses for terminating, manual cutting machines and all of our boards are stationary.
We are at a lose in what to implement for predictive maintenance. Does anybody have any suggestions. Thanks.

Edit: Just to let you know, our plant is in Mexico and I really don't know what services are available where we are.

Some examples of predictive maintenance are thermal imaging to detect mechanical or electrical components that are running hotter than normal; analysis of fluids (hydraulic) for chemical breakdown, metal fines, contamination; vibration or acoustic analysis (bearings, alignment of rotating equipment, etc.).

There are other techniques.

Some examples of predictive maintenance are thermal imaging to detect mechanical or electrical components that are running hotter than normal; analysis of fluids (hydraulic) for chemical breakdown, metal fines, contamination; vibration or acoustic analysis (bearings, alignment of rotating equipment, etc.).

There are other techniques.

What are the other techniques. The three you listed are the only three that we hear about and it is really not cost effective based on the equipment that we have. We do not have rotating equipment, we don't have hydraulic fluids and very little mechanical equipment.

We have Komax cutting machines, compressors, presses for terminating, manual cutting machines QA-Talport, the question to ask is: which functions of these machines affects quality?

Planning for preventive maintenance is planning for realiable and continual good output for the tool's availability as well as ability to produce good product.

Thus, the questions to ask for planning are:

1. Which functions would affect readiness--that is, which would cause down time if the machine breaks and is not available?
2. Which functions would affect ability to produce good product if wear, misalignment, malfunction due to mechanical problems etc. occurs? This requires understanding of what machine aspect impacts what quality aspect.

An FMEA should help you with this planning process.

If the technological aspects to Predictive Maintenance aren't feasible, what about the people aspects? Have you introduced a Routine Equipment Care program for your operators to follow, so that Maintenance personnel can do maintenance? This initiative helps the operator to understand his/her equipement and its use, plus improves communication between Operations and Maintenance.

If done properly, the number and length of interruptions may be reduced, as well as the number of equipment emergencies.

Have you also established Key Performance Indicators to track equipment performance, utilizations, delays, etc.? Highlighting problem areas (i.e., trends) will assist you in developing a more proactive maintenance program instead of reactive.

This is great information for preventive maintenance, but I am really looking for some predictive maintenance ideas.

Predictive and preventive are similar in that both are meant to prevent disruptions.

Predictive could be thought of as a guess as to when failure would happen, and do a repair before then. Wear, vibration and other trends would be examined.

Preventive would be more routine, like changing belts, filters and oil, and cleaning.

Read more about predictive maintenance here:
http://www.idcon.com/article-maintenancetwoeight.htm
http://www.plantservices.com/articles/2005/479.html
http://www.allbusiness.com/marketing-advertising/marketing-collateral/217498-1.html
...and also here (http://books.google.com/books?id=SjqXzxpAzSQC&pg=PA356&lpg=PA356&dq=planning+predictive+maintenance&source=web&ots=iBvQNJKnbh&sig=otN4SmfIXU1jrNYRl6rByNwKReM#PPP1,M1).

Links to similiar discussions where you might obtain some ideas can also be found by scrolling down to the bottom of this screen.

Predictive and preventive are similar in that both are meant to prevent disruptions.

Predictive could be thought of as a guess as to when failure would happen, and do a repair before then. Wear, vibration and other trends would be examined.

Preventive would be more routine, like changing belts, filters and oil, and cleaning.

A couple of existing threads to gum up the works:

Distinction between Preventive Maintenance and Predictive Maintenance (http://elsmar.com/Forums/showthread.php?t=19054)
Predictive maintenance vs Preventive maintenance (http://elsmar.com/Forums/showthread.php?t=20412)
Preventive vs. Predictive Maintenance - What is the difference? TS 16949 - 7.5.1.4 (http://elsmar.com/Forums/showthread.php?t=5000)

Most items we use are Preventive. With respect to the predictive maintenance I agree with Miner. We use the vibration and thermal imaging of electrical panels and disconnect boxes. Thermal imaging is very good at detecting potential fire hazards and therefore potential downtime and operational disruptions.

You could probably ask your auditor what type of predictive items they have seen as well to get an idea of what else is out there.

The thermal testing works well, we generally find items each year based on this function. Vibration testing has not been as beneficial to us.

Good luck.
Jason.

My question is: just because predictive maintenance is mentioned in the TS documents, does it mean that every body must practice it or show evidence that it is being practiced?

While I understand that it is basically a 'good practice' but at times it may not be applicable in a low tech. environment such as manufacturing of wire harness where simple machines for cutting, crimping and testing are employed. (in other words, traditional preventive maintenance is good enough)

Thanks in advance for sharing your views.

What are the other techniques. The three you listed are the only three that we hear about and it is really not cost effective based on the equipment that we have. We do not have rotating equipment, we don't have hydraulic fluids and very little mechanical equipment.

Sorry. I didn't have time earlier to get back with you.

Some additional methods include dynamic current monitoring of motors, continual monitoring of temperature for gradual increases, continual monitoring of pressure or pressure drop (as filters clog), ultrasonic, and performance trending.

In answer to you question Harry:

The requirement for Predictive Maintenance is a Shall and therefore you must do it.

Section 7.5.1.4 "The Organization shall utilize predictive maintenance methods to continually improve the effectiveness and the efficiency of production equipment."

Therefore the focus should be on production equipment, and you must show evidence that even low tech items have predictive maintenance performed.

It is a good question and did make me look at the specification to ensure I wasn't missing anything.

Couldn't something as simple as visual inspection be a part of predictive maintenance? Between shifts someone goes around and looks at the equipment for signs of wear and tear. Items that are questionable are watched more closely, or are replaced immediately.

Who has the signature "Low Tech is better than No Tech"?

I think the system belongs to the owner who runs the business, as such whether Predictive Maintenance is practical for the owner is at his discretion base on his cost and benefit analysis.

I agree that simple routine preventive maintenance's resulta contribute to the predictive maintenance decision. If the components found to fail soon can be replaced readily without causing disruption to quality and delivery to customer, I think it is less critical to practice predictive maintenance here.

I agree, predictive maintenance is good to practice when components of machines are not changed before it fails as it could cause the owner to incur most cost, but not for those with easy replacement of components and quick repaired machines. If this is already acceptable in TS audit, please enlighten me, thank you very much!

As such, I wonder whether TS Standard would consider revising some of the requirements to be more flexible, of course it will then depend on competence of auditor to judge whether the practice of the owner is complying to the intent of the Standard; and I think auditor is and should play this role, instead of follow the standard without critical assessment of the Standard requirement and its applicability.

Please pardon me and correct me for me to learn more, thank you very much!